Drapery fabrics and methods of making the same

ABSTRACT

Methods of forming stabilized, open-weave drapery fabrics having excellent surface coverage, high color intensity, and low light penetration per unit weight comprising: weaving an open-weave drapery fabric from (1) a warp containing from about 16 to about 24 ends per inch of relatively flattened oval strip or ribbon saran having an average thickness of from about 1 1/2 mils to about 3 mils and an average width of from about 20 mils to about 35 mils and (2) a filling of modacrylic yarns having a yarn size of from about 8/1 to about 4/1 cotton count, there being from about 12 to about 16 filling picks per inch; and calendering said open-weave drapery fabric at elevated temperatures and under sufficient pressure as to flatten the filling yarns; and the resulting stabilized, open-weave drapery fabrics.

United States Patent Dean Nov. 11, 1975 DRAPERY FABRICS AND METHODS OF3,327,468 6/1967 Page 57/140 R MAKING THE SAME 3,549,470 12/1970Greenwald et a1 28/72 FT I 3,606,914 9/1971 Maiwald et a1. 139/420 RInventor: am Bruce an, 3,716,446 2/1973 Dean 139/420 R [73] AssigneezJohnson & Johnson, New 3,731,351 5/1973 Kocay et al. 28/76 R BrunswlckPrimary Examiner-James Kee Chi [22] Filed: Apr. 4, 1973 21 Appl. No.2347,934 [57] TR Methods of forming stabilized, open-weave draperyfabrics having excellent surface coverage, high color [52] US. Cl; 28/72FT; 139/420 R intensity and low light penetration per unit weight [51]Int. Cl.- D06C /00; D03D 15/00 comprising: weaving an Open weave draperyfabric [58] Fleld 0f Search 139/420 R, 420 A, 426 R, from 1 a warpcontaining f about 1 to about 24 139/383 R; 28/72 R, 72 FT; 161/91, 92ends per inch of relatively flattened oval strip or rib- 57/140 140 Ibon saran having an average thickness of from about 1 /2 mils to about 3mils and an average width of from [56] References Clted about mils toabout mils and (2) a filling of UNITED STATES PATENTS modacrylic yarnshaving a yarn size of from about 8/1 2,312,089 2/1943 GObellle 139/420 Ato about ton count, there ng r m a ut 12 2,354,435 7/1944 Stedman139/420 R to about 16 filling ,picks per inch; and calendering said2,712,170 7/1955 Phillips 28/76 R open-weave drapery fabric at elevatedtemperatures 2712334 7/1955 Black et 139/426 R and under sufficientpressure as to flatten the filling 2,768,652 10/1956 Hendley 139/420 Ryams; and the resulting stabilized Open weave drap 2,812,782 11/1957Stevens 1 139/420 R y fabrics 2,903,021 9/1959 Holden et a1. 139/426 R I3,033,239 5/1962 Kenin 139/420 R 4 Cla'ims, 4 Drawing Figures 2.. 2.. tI I l I /Z DRAPERY FABRICS AND METHODS OF MAKING THE SAME Draperyfabrics include decorative and functional textile materials, such ascurtains, drapes, hangings, and the like, which are generally suspendedand hang loosely from rods, rails, hangers, hooks, and the like. Draperyfabrics should be light in weight but must possess sufficient weightproperties as to physically hang and drape properly. Drapery fabricsshould also possess sufficient surface coverage, color intensity and lowlight penetration as to afford necessary esthetic and functionalcharacteristics and, or course, be economical to manufacture.

Many of these requirements are diametrically opposed to each other anddrapery fabrics have therefore generally combined a compromise of mostof these conflicting requirements. The purpose and object of the presentinvention is therefore to combine as many of these properties in draperyfabrics without substantially losing any one of the required oressential properties and characteristics.

It has been found that such purpose and object and others which willbecome clear from a further reading of this disclosure may be achievedby the improved methods of the present invention which involve weavingan open-weave drapery fabric from (1) a warp containing from about 16 toabout 24 ends per inch of relatively flattened oval strip or ribbonsaran having an average thickness of from about 1 /2 mils to about 3mils and an average width of from about 20 mils to about 35 mils and (2)a filling of modacrylic yarns having a yarn size of from about 8/1 toabout 4/1 cotton count, there being from about 12 to about 16 picks perinch; and calendering the resulting open-weave drapery fabric atelevated temperatures and under sufficient pressure as to soften, moldand generally flatten the filling yarns.

The resulting fabrics, when made into drapery fabrics, are found topossess the necessary properties and characteristics of good hanging anddrape qualities, excellent surface coverage, color intensity and lowlight penetration per unit weight, along with excellent economy ofmanufacture.

In the following specification and accompanying drawings, there aredescribed and illustrated preferred embodiments of the invention but itis to be understood that the inventive concept is not to be consideredlimited to the embodiments disclosed except as determined by the scopeof the appended claims. Referring to the accompanying drawings:

FIG. 1 is a fragmentary schematic flow chart depicting the manufacturingmethod of the present invention;

FIG. 2 is a cross section of one of the relatively flattened oval stripsaran warp materials taken at right angles to the long axis of the flatstrip;

FIG. 3 is a cross section of one of the modacrylic filling yarns priorto weaving and calendering, taken at right angles to the long axis ofthe filling yarn, showing its generally round or circular crosssections; and

FIG. 4 is a cross section of one of the modacrylic filling yarnssubsequent to calendering, taken at right angles to the long axis of thefilling yarn, showing its generally flattened cross section.

With reference to the drawings and particularly FIG. 1 therein, there isschematically shown a conventional loom 10 into which a warp sheet ofrelatively flattened oval strip saran ribbons 12 is fed in conventionalfashion.

WARP

The warp is made of saran ribbons of relatively flattened oval stripmaterials 12 having an average thickness of from about 1 /2 mils toabout 3 mils and an aver age width of from about 20 mils to about 35mils. A typical cross section is shown in FIG. 2. The warp sheetcontains from about 16 to about 24 ends per inch and is thus relativelyan openly spaced warp. Its width is generally in the range of from about30 inches to about 84 inches.

As used herein, the word saran is a generic term for a manufacturedfiber in which the fiber-forming substance is any long chain syntheticpolymer composed of at least per cent by weight of vinylidene chlorideunits (-CH CCI Saran will not support combustion and isself-extinguishable. It has a specific gravity of 1.7, a moisture regainof only 0.1, a softening or sticking point of from about 240 to about320F., and a melting point of from about 335 to about 350F.

Modacrylic filling yarns 14 are interwoven with the relatively flattenedoval strip saran warp ribbons 12 in conventional weaving fashion and theresulting is an open-weave fabric 16.

FILLING The filling yarns 14 are made of modacrylic yarns in the yarnsize range of from about 8/ 1 to about 4/1 cotton count, or as is oftenstated 8s yarns single to 4s yarn single. A typical round or circularcross section, prior to weaving, is shown in FIG. 2. Such yarn numbers,of course, indicate the number of hanks per pound, as is well known inthe textile and related industIl6S.'

The filling yarns 14 are preferably spun from staple modacrylic fibershaving an average denier of from about 1 to about 3, although bulkedmultifilamentary modacrylic yarns may also be used having a size andweight equivalent to the cotton count range set forth hereinabove.

As used herein, the word modacrylic is the generic name for amanufactured fiber in which the fiberforming substance is any long chainsynthetic polymer composed of less than about 85 per cent, but at leastabout 35 per cent, by weight of acrylonitrile units except when the termqualifies as rubber or anidex. Dynel is the most popular known trademarkfor modacrylic spun yarns, multifilaments, and monofilaments.Modacrylics will not support combustion and are selfextinguishable. Theyhave specific gravities from about 1.30 to about 1.36, softening orsticking temperatures of from about 250 to about 325F., which isconsidered as its moldable range.

The resulting fabric 16, when made up into drapery fabrics so that thewarp of relatively flattened oval strip or ribbon saran materials hangsvertically, thus enhances the hanging and drape qualities and representsan excellent improvement over existing drapery fabrics. Such improvementis all the more increased when the fabric is exposed to a subsequentcalendering process under heavy pressure and elevated temperature forthe purpose of flattening the modacrylic spun yarn into the plane of thedrapery fabric. This flattening of the filling yarn and its molding intoa relatively flattened cross-section, such as illustrated in FIG. 4 ofthe drawings, is a feature of the present invention.

CALENDERING As shown in FIG. 1, the open-weave fabric 16 is fed into aconventional calender, l8. Calendering is essentially an ironing processwherein fabric is continuously run through the press nip of at least tworotating heated, pressure-applying rolls of a calender which is a heavyweight textile machine. One of the rotating rolls is usually made of ahard material such as chilled steel; the other roll is quite often madeof a softer material. The rolls are adapted to be heated usuallyinternally by gas, electric, or steam to any desired elevatedtemperature which in the present invention is sufficient to bring thefabric surface temperature into the range of from about 250 to about300F.

The rolls exert considerable pressure upon the fabric 16 passingtherethrough, which, in the present invention, is in the range of fromabout to about 60 tons as exerted against a fabric having a width ofabout 48 inches, for example. Heavier calenders, capable of exerting upto 100 tons across the full width of the fabric may also be used, ifdesired or required. The fabric passing through such calenders may moveat a rate as low as about 50 yards per minute or less up to about 200yards per minute or more depending upon the cir cumstances involved.

If desired, the fabric 16 may be passed through the nip several timesfor successive pressings and moldings. Following the calenderingprocess, the calendered fab ric 16' is then wound up on take-up rolls atthe back of the calendering machine.

During the calendering, the modacrylic filling yarns 14 which areoriginally more or less round or circular in cross section, as shown inFIG. 3, are flattened as shown in FIG. 4 so that they are morerelatively flattened oval and lie more within the plane of the fabricand possess less or no tendency to roll or move out of or shift from theposition as originally woven.

Additionally, these relatively flattened oval modacrylic filling yarns14', with their relatively flat upper and lower surfaces, along with theflat surfaces of the flat strip saran warp 12 provide excellent surfacecoverage, high color intensity and low light penetration per unit weightof fabric.

And, it is also to be noted that the calendered fabric is flatter andmore planar and yields a more pleasing view to the eye and a betterhand.

The inventionwill be further illustrated in greater detail by thefollowing specific examples. It should be understood, however, thatalthough these examples may describe in particular detail some of themore specific features of the invention, they are given primarily forpurposes of illustration and the invention in its broader aspects is notto be construed as limited thereto.

EXAMPLE I Drapery fabric is made up to the following specifications: 2%mils X 28 mils saran relatively flattened oval strip warp, 18 ends perinch; 8/1 Dynel modacrylic filling yarns, polymerized from approximately40% acrylonitrile and approximately 60% vinyl chloride, 14 picks perinch; weight of fabric is 0.226 poundsper linear yard; 48 inches wide.Calendering pressure is l-nip, 40 tons across the 48 inch width at atemperature of about 270F.

Drapery fabric made therefrom is stabilized and possesses excellentsurface coverage, high color intensity and low light penetration perunit weight. It is flame re-. tardant. Inspection of the fabric revealsthat the modacrylic spun yarns are flattened and actually molded into arelatively flattened .oval cross sectional shape in the plane of thefabric at the pressure and temperature which is exerted duringcalendering.

EXAMPLE II Drapery fabric is made up to the following specifications: 2%mils X 28 mils saran relatively flattened oval.

strip warp, l8 ends per inch;6/l Dynel modacrylic filling yarns (40%acrylonitrileand 60% vinyl chloride); 14 picks per inch; weight offabric is 0.287 pounds per linear yard; 48 inches wide. Calenderingpressure is l-nip, 40 tons across the 48 inch width at a temperature ofabout 270F. v

Drapery fabric made therefrom is stabilized and possesses excellentsurface coverage, high color intensity and low light penetration perunit weight. It is flame retardant. Inspection of the fabric revealsthat the -mod-' acrylic spun yarns are flattened and actually moldedinto an elliptical or oval cross sectional shape in the plane of thefabric at the pressure and temperature which is exerted duringcalendering.

EXAMPLE III I Drapery fabric is made up to the following specifications:2% mils X 28 saran relatively flattened oval strip I warp, 18 ends perinch; 4/1 Dynel modacrylic filling yarns (40% acrylonitrile and 60%vinyl chloride), 14 picks per inch; weight of fabric is 0.336 poundsperlinear yard; 48 inches wide. Calende ring pressure is l-nip, 40 tonsacross the 48 inch width at a temperature of. about 270F.

Drapery fabric made therefrom is stabilized and possesses excellentsurface coverage, high color intensity and low light penetration perunit weight. It is flame re- I tardant. Inspection of the fabric revealsthat the modacrylic spun yarns are flattened and actually molded I intoa relatively flatly elliptical or oval cross sectional shape in theplane of the fabric at the pressure and temperature which is exertedduring calendering.

Although several specific examples of the inventive concept have beendescribed, the same should not be consisting of the following steps inthe sequence set forth: weaving an open-weave drapery fabric from (1) awarp containing from about 16 to about 24 ends per inch of relativelyflattened oval strip saran having an I average thickness of from about1V2 mils to about3 mils and an average width of from about 20 mils toabout 35 mils and (2) a filling of substantially round modacrylic yarnshaving a yarn size of from 8/1 to about 4/1 cotton count, there beingabout 12 to about 16 picks per inch; and calendering said open-weavedrapery fabric at elevated temperatures of from about 250F to about 350Fand under pressures of from 6 about tons to about 100 tons per 48 inchesof fabric 3. A method as defined in claim 1 wherein the filling width asto soften, mold and flatten the filling yarns. yarns are flattened intoan oval cross-sectional shape. 2. A method as defined in claim 1 whereinthe mod- 4. A method as defined in claim 1 wherein the filling acrylicfilling yarn is Dynel," a copolymer of about yarns are flattened into anoval cross-sectional shape in 40% by weight of acrylonitrile and about60% by 5 the plane of said drapery fabric.

weight of vinyl chloride.

1. A method of forming a stabilized open-weave drapery fabric havingexcellent surface coverage, high color intensity and low lightpenetration per unit weight consisting of the following steps in thesequence set forth: weaving an open-weave drapery fabric from (1) a warpcontaining from about 16 to about 24 ends per inch of relativelyflattened oval strip saran having an average thickness of from about 11/2 mils to about 3 mils and an average width of from about 20 mils toabout 35 mils and (2) a filling of substantially round modacrylic yarnshaving a yarn size of from 8/1 to about 4/1 cotton count, there beingabout 12 to about 16 picks per inch; and calendering said open-weavedrapery fabric at elevated temperatures of from about 250*F to about350*F and under pressures of from about 20 tons to about 100 tons per 48inches of fabric width as to soften, mold and flatten the filling yarns.2. A method as defined in claim 1 wherein the modacrylic filling yarn is''''Dynel,'''' a copolymer of about 40% by weight of acrylonitrile andabout 60% by weight of vinyl chloride.
 3. A method as defined in claim 1wherein the filling yarns are flattened into an oval cross-sectionalshape.
 4. A method as defined in claim 1 wherein the filling yarns areflattened into an oval cross-sectional shape in the plane of saiddrapery fabric.